2. Fervi
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Fervi 0237/05, 0237/15 Use and Maintenance Manual

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USE AND
MAINTENANCE MANUAL
Paranco a leva
Art. 0237/05, 0237/15
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
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PREFACE
Please ensure you have r
ead this manual before operation
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
It is compulsory to read this instruction manual before starting operation. The guarantee that
the machine will function and perform properly is strictly dependent upon the applicat
ion of all
the instructions contained in this manual.
Operator Qualifications
The workers responsible for the use of this machine must have all the necessary
information and instruction and should be given adequate training in relation to safety
reg
arding:
a)
Conditions of use for the equipment;
b)
Foreseeable abnormal situations, pursuant to Article 73 of Legislative Decree
81/08.
We guarantee the Machine complies with the specifications and technical instructions
described in the Manual on the date of
issuance and listed herein; On the other hand,
the machine may also be subject to important technical changes in the future, without
the Manual being updated.
Therefore, contact FERVI for information about modifications that may have been
implemented.
REV. 1
September 2013
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CONTENTS
1
INTRODUCTION
................................
................................
........................
4
1.1
Preface
................................
................................
................................
..........................
5
2
SA
FETY WARNINGS
................................
................................
..................
6
2.1
General safety rules for machine equipment
................................
................................
.
6
2.2
Safety rules for lever chain hoists
................................
................................
.................
7
2.3
Technical support
................................
................................
................................
..........
7
2.4
Other provisions
................................
................................
................................
...........
7
3
HOIST DESCRIPTION
................................
................................
................
8
3.1
Technical specifications
................................
................................
................................
8
3.2
Major Components
................................
................................
................................
........
9
3.3
Identification plate
................................
................................
................................
.....
10
3.4
Operating controls
................................
................................
................................
......
11
3.5
Safety devices
................................
................................
................................
.............
12
4
MISUSE AND
CONTRAINDICATIONS
................................
.......................
13
5
TRANSPORTATION, LIFT
ING AND MOVING
................................
.............
13
6
COMMISSIONING
................................
................................
....................
14
6.1
General warnings
................................
................................
................................
........
14
6.2
Installation
................................
................................
................................
.................
14
6.3
Preliminary testing
................................
................................
................................
.....
14
7
MACHINE OPERATION
................................
................................
.............
15
7.1
Lifting a load
................................
................................
................................
...............
15
7.2
Lowering a load
................................
................................
................................
..........
17
8
MAINTENANCE
................................
................................
........................
18
8.1
Routine maintenance
................................
................................
................................
..
18
9
TROUBLESHOOTING
................................
................................
................
20
10
DECOMMISSIONING
................................
................................
.............
20
10.1
Machine downtime
................................
................................
................................
...
20
10.2
Disassembly and disposal of materials and compon
ents
................................
..........
20
11
REPLACEMENT PARTS
................................
................................
...........
21
12
CONTROL REGISTER
................................
................................
.............
24
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1
INTRODUCTION
This manual is considered
an integral part of the machine it was attached to at the time of
purchase.
The manufacturer holds all ownership to material and intellectual property of this manual;
any disclosure or copying, even partial, of this publication without prior written conse
nt is
forbidden.
The purpose of this manual is to provide the knowledge necessary for the use and
maintenance of the machine
Paranco a leva
Art. 0237/05, 02
37/15
and c
reate a sense
of responsibility and an understanding of the capabilities and limitations of the means
entrusted to the operator.
As the machine is entrusted to experienced and skilled operators, the following machine must
be perfectly known by the operator
if you want it to be used safely and effectively.
Operators must be properly trained and prepared, so make sure that this manual is read and
consulted by the staff responsible for commissioning, operation and maintenance of the
Paranco a leva
.
This is to make all operations the safest and most effective possible for
those who carry out these tasks.
Therefore, it is imperative to strictly comply with the requirements in this manual, a
necessary condition for safe
and satisfactory operation of the machine.
Before starting operation, installation and use of the
Paranco a leva
, authorized staff must
therefore:
read this technical document carefully;
know which protections an
d safety devices are available on the machines, their location
and how they work.
The buyer is responsible for ensuring that users are properly trained, that they are aware of
all the information and instructions in this document and that they are aware o
f the potential
risks of operating the
Paranco a leva
.
The manufacturer waives any and all responsibility for damage to people and/or
things caused by non
-
observance of the instructions in this manual.
The
Paranco a leva
has been designed and built with mechanical guards and safety devices
designed to protect the operator/user from possible injury. It is strictly forbidden to modify or
remove guards, safety devices and
caution labels. If this must be done (for example, for
cleaning or repair), make sure that no one can use the machine.
Modifications to the machines carried out by the user must be considered their sole
responsibility, therefore the manufacturer decline
s all responsibility for any damage
caused to persons and/or property resulting from maintenance performed by
unqualified personnel and in a manner different from the operating procedures
shown below.
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G
RAPHIC REPRESENTATIO
N OF SAFETY
,
OPERATIONAL AND RIS
K WARNINGS
The following boxes are designed to attract the attention of the reader / user for the
proper
and
safe
use of the machine:
Pay Attention
This highlights behavioural rules to prevent damage to the machine and/or the occurrence of
dangerous si
tuations.
Residual Risks
This highlights the presence of dangers that cause residual risks to which the operator must
pay attention in order to avoid injury or damage to property.
1.1
Preface
For safe and easy operation of the
Paranco a leva
, this manual must be read carefully in
order to acquire the necessary knowledge. In other words, durability and performance are
strictly dependent on how it is used.
Even if already familiar with the
Paranco a leva
, it is necessary to follow the instructions
contained herein, in addition to the general precautions to be observed while working.
Acquire full knowledge of the machine.
Read this manual carefully to understand: operation
, safety devices and all necessary
precautions. All this is to allow safe use of the machine.
Wear appropriate clothing for the job.
The operator must wear appropriate clothing to prevent the occurrence of unforeseen
accidents.
Maintain the machine with ca
re.
Using the Machine
The machine must only be used by qualified personnel trained to use the machine by
authorized personnel.
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2
SAFETY WARNINGS
2.1
General safety rules for machine equipment
Risks associated with using the machine
DO NOT underestimat
e the risks associated with using the machine and concentrate on the
work in progress.
Risks associated with using the machine
Despite the implementation of all the safety devices for safe use of the machine, it is
necessary to take note of all the re
quirements for the prevention of accidents reported in
various parts of this manual.
Risks associated with using the machine
Every person who is responsible for the use and maintenance of the machine should have first
read the instruction manual, par
ticularly the chapter on safety information.
It is recommended that the plant safety manager get written confirmation of the above.
Risks associated with using the machine
During all work phases with the machine, you should proceed with great caution
in
order to avoid damage to persons, to the property or to the machine itself.
Please only use the machine for its envisaged uses.
Don't tamper with the safety devices equipping the machine.
Risks associated with using the machine
Before starting any
work on the machine, the operator must wear the appropriate personal
protective equipment (PPE) such as gloves and eye protection.
1.
Always check the efficiency and integrity of the machine.
2.
Keep the workplace tidy and free from obstruction; disorder cause
s accidents.
3.
Make sure that your work environment is forbidden to children, strangers and animals.
4.
Do not perform tasks on the machine other than those for which it was designed. Only
use the machine in the manner in which it was intended, as described in
this instruction
manual.
5.
Work without disturbances.
6.
Work areas must be well lit.
7.
Always wear eye protection and protective gloves while working. If dust is produced,
use the appropriate masks.
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8.
Wear appropriate clothing. Loose clothing, dangling jewellery,
long hair, etc.., can get
caught in the moving parts, causing irreparable injury.
9.
Replace worn and/or damaged parts, check that the guards and protection devices work
properly before operating. If necessary, have the machine checked by the service
support
personnel. Use only original spare parts.
10.
Do not use the machine in areas with a risk of fire and/or explosion.
11.
It is recommended that users of this publication, for maintenance and repair, have a
basic knowledge of the mechanical principles and procedures
inherent in repair
technique.
12.
The company safety officer is required to make sure that machine operators
have read and understood this manual in its entirety.
13.
The company safety manager is responsible for monitoring the company's risk
status according to
Legislative Decree no. 81/08.
2.2
Safety rules for lever chain hoists
1.
Do not try to operate the machine at higher performance levels than those for which it
was designed,
in particular regarding the magnitude of the load to be lifted.
In
other words, do not
load the Hoist beyond its capacity.
2.
Use the hoist exclusively for lifting, and only in the intended manner and use described
in this instruction manual.
3.
Before lifting, always check:
the efficiency and integrity of the machine, and in particular the hooks,
the
loading chain and brake;
the strength and integrity of the support structure to which the machine is
attached (truss, crane arm, etc);
2.3
Technical support
For any problems or concerns, please contact, without hesitation the Technical Support
Department
of your dealer, who has competent and specialised staff, specific equipment and
spare parts.
2.4
Other provisions
I
T IS FORBIDDEN TO TA
MPER WITH SAFETY DEV
ICES
Check the presence and integrity of protections and the proper functioning of safety devices
before
starting operation.
If any defect is encountered do not use the machine!
It is absolutely forbidden, therefore, to modify or remove the guards, safety
devices, labels and information plates.
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3
HOIST DESCRIPTION
The Lever chain hoist is a portable manuall
y operated piece of equipment. It is, therefore,
particularly suitable for all temporary applications, which take place indoors or outdoors and
where there is no electricity network, such as: warehouses, construction sites, farms, mines,
quarries, ports an
d shipyards.
The machine must be attached to a support structure with sufficient strength such as: fixed
or movable arms of other lifting devices or support structures.
The machine can be used outdoors if it is protected from the weather and especially fr
om the
effects of the wind.
The operating temperature is within the range of
20 / +50 °C.
The environment must also be sufficiently illuminated so as to ensure operation in maximum
safety (at least 200 lux is recommended).
Other types of use, or the ext
ension of use beyond that envisaged, does not
correspond to the designation attributed by the manufacturer, and therefore the
latter cannot accept any responsibility for any damage resulting therefrom.
3.1
Technical specifications
Description (unit of measure
ment)
237/05
237/15
Load capacity (kg)
500
1500
Maximum lifting height (mm)
1500
Load chain diameter (mm)
5
7
Minimum distance between the hooks (mm)
300
400
Control lever length (mm)
253
378
Weight (kg)
5
12
Lever travel to achieve elevation of max
imum permissible load
(N)
248
295
Number of load chains
1
Load test (kg)
750
2250
Size (mm)
A
143
A
173
B
86
B
99
C
118
C
145
Ø
35
Ø
42.5
E
27
E
35
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3.2
Ma
in
Components
Figure
1
Overvi
ew of the Machine
1
Load hook
5
Control lever
2
Hoist mounting hook
6
Up/Down switch
3
Load chain
7
Chain pretensioner
4
Gear lock
8
Chain travel limit ring
1
3
4
6
2
7
5
8
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3.3
Identification plate
On the machine there is an identification plate like the one shown bel
ow:
Figure
2
Identification Plates
M
AXIMUM LOAD CAPACITY
VALUE
The plate shows the
maximum load capacity
.
This maximum load capacity must not be exceeded under any circumstance.
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3.4
Operating controls
Errore. Il segnalibro non è definito.
On the box, on the operating chain, the following controls are present, for the use of the
hoist:
The
selector lever
for the upward or downward movement of the load.
The
pretensioner
of the load chain.
The
selector lever
for the upward or
downward movement of the load, controls the raising
or lowering of the load. The control has three different positions:
1.
UP
2.
N (Neutral)
3.
DOWN
The control, when put in the UP position, allows the load to be
lifted, to lower it the control is put in the DOWN
position.
Position N, allows us to disengage the safety brake device
leaving the load chain free to slide, enabling adjustments to
its length to be carried out, according on the work to be
performed.
Figure
3
Up/Down selec
tor lever.
The
pretensioner
of the load chain, allows the tension to be
adjusted or for the chain to be released, before lifting the load or
after having placed it on the ground.
To tighten the chain, after attaching the hoist to a suitable support
struc
ture and with the load ready to be lifted, rotate the
appropriate control clockwise until the pre
tensioning of the chain
has been fully carried out. To release the chain, after placing the
lifted load on the ground, rotate the appropriate control
anticloc
kwise until the chain has been completely released.
Figure
4
–
Load chain pretensioner.
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3.5
Safety devices
Errore. Il segnalibro non è definito.
The main safety devices on the machine are:
The
safety brake.
The
safety locking device for both hooks
, to prevent the hoist and/or the load from
detaching during normal operation (see
Figure
5
);
The
safety brake
, is constituted by a ratchet gear with two clutch discs, connected to the
operating chain. This
Errore. Il segn
alibro non è definito.
ensures a "gradual and controlled"
lowering of the load.
The
safety locking device of the hooks
(see
Figure
5
), protects against hazards due to the
accidental uncoupling of the hoist from the suppor
t structure and/or load from the load hook;
during lifting / lowering.
Figure
5
Locking device.
Use of P.P.E.
In any case, ALWAYS use appropriate personal protective equipment such as safety gloves
and shoes and,
if necessary, a protective hard hat.
Figure
6
Personal Protective Equipment.
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4
MISUSE AND CONTRAIND
ICATIONS
The following actions described, which obviously can not cover the entire range of potential
possibilities o
f "misuse" of the machine, are to be considered
strictly prohibited.
THE FOLLOWING IS STRICTLY PROHIBITED!
To operate and/or stand under the load. Specifically, during lifting operations, the
operator must be near the hoist to operate the push
button c
ontrol panel without
standing under the load;
To lift persons and/or animals that could fall;
To lift loads while there are people near the machine;
To lift loads that weigh more than the
NOMINAL MAXIMUM LOAD
CAPACITY
of the lever
chain hoist indicated on
the label.
To lift unbalanced loads and/or loads which may change their static configuration
and/or their centre of gravity;
To lift the load to a height greater than strictly necessary;
To lift the load without checking that the hooks safety latch locks p
erfectly;
To lift loads using harness systems that are not suitable;
To attach the hoist to a fixed structure or to another lifting device of insufficient
strength (compared to the maximum nominal loading capacity + weight of the hoist);
To use the hoist f
or operations where there is a possibility of accidental load shift;
To leave the loaded hoist unattended;
To perform sudden manoeuvres with the hoist;
To keep the operating chain oblique during use;
To completely wrap the load chain, so that the hook can
strike against the body of the
hoist;
To allow hoist operation by untrained personnel;
To operate the hoist if you are not psycho
physically fit;
To operate the hoist without due attention;
To operate the crane for purposes other than those for which it w
as designed;
To operate the hoist in adverse and/or unforeseen environmental conditions (strong
winds, low light etc.);
To operate the hoist in insufficient lighting.
5
TRANSPORTATION, LIFT
ING AND MOVING
The hoist can be moved manually by a single operator
for transport (machine weight < 25
kg).
Before moving the hoist, it is necessary to completely wrap the load chain and the operating
chain.
Errore. Il segnalibro non è definito.
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6
COMMISSIONING
6.1
General warnings
The following chapters are the core of the manual, and contain the
actual operating
instructions on how to install, operate and maintain the Lever chain hoist.
Proper machine installation and commissioning is extremely important and constitutes a
serious risk to the safety of people exposed at this stage or with subseque
nt use of the
machine if poorly executed.
6.2
Installation
The
Lever chain hoist
must be mounted on a suitable
support structure, with adequate resistance
characteristics. This structure must, in fact, be able to
support the
weight of the hoist plus the maxim
um
nominal loading capacity
(which is more than 1500 kg
in the case of art. 0237/15).
The following can be used in this regard:
beams and/or similar fixed structures;
parts of other lifting devices such as jib cranes,
overhead cranes, etc.;
Hook the upper
hook, for attaching the hoist to the
support structure to the structure itself; after which
prepare the chains so that they are loose and fully
stretched out (no twisting).
Figure
7
–
Hoist installation.
Hoist attachment hoo
k
Check the connection of the hoist attachment hook and the perfect closing of the safety latch.
6.3
Preliminary testing
Errore. Il segnalibro non è definito.
Before using the machine it is necessary and essential to carry out preliminary testing in its
place of use.
Th
e test includes:
a general visual inspection of the machine to make sure there are no damaged and/or
worn parts on the structure itself, chains, hooks, etc.;
the proper arrangement of the chains (they should not be rolled or twisted);
a verification that t
he machine functions properly making it perform a few complete
cycles (the entire stroke of the lifting chain) of lifting/lowering unladen (i.e. without a
load);
an operating test of the safety brake, making it perform a few complete descent cycles
with sm
all loads (max 10 kg).
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7
MACHINE OPERATION
7.1
Lifting a load
Errore. Il segnalibro non è definito.
Lifting loads
There is a risk of crushing body parts while moving heavy loads resulting from mishandling.
Workers must be equipped with standard safety equipment, especia
lly crush resistant gloves
and safety shoes and a protective hard hat.
Lifting loads
Workers performing the lifting of loads must guide the device carefully, without abrupt
movements with using the utmost care. In particular, the hoist and the load mu
st be kept
under constant control during movement.
Working under loads
Working with a lifted load ALWAYS entails a residual risk of the load falling
accidentally.
In this regard, it is STRICTLY FORBIDDEN to operate and/or stand under the lifted
load.
Make sure that the load to be lifted weight is not greater than the maximum permitted.
Thoroughly inspect the lever chain hoist and all its parts, in particular checking the
hook, the load chain, the braking system and the correct lubrication of the equi
pment.
Only use the lifting hoist if has successfully passed a check testing its operating
condition.
Attach the load hook to the load to be lifted and make sure it is properly attached.
Hooking the load
Check the connection of the hoist load hook and
the perfect closing of the safety latch.
Do not attach the load to the tip of the hook or hang the hook obliquely.
For proper use, the lifting chain must be perfectly vertical.
Move the up/down selector lever to the N position, then rotate the chain pret
ensioner
control clockwise until the chain is full tensioned, or pull the chain travel limit ring as
far as the automatic coupling of the safety brake (
Figure
8
).
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Figure
8
–
Chain pret
ensioner.
Working under loads
IT IS STRICTLY FORBIDDEN to operate and/or stand under the load.
To lift the load move the up/down selector lever to UP, then pull the
control lever up and down in alternating movements (see Figure 9).
Figure
9
–
Hoist installation.
Impediments to lifting operations
Immediately stop using the hoist in the event it is no longer possible to pull the control
lever.
Carry out the following checks, which does not require the help of anot
her person:
o
If something has caught on the load;
o
If a part of the hoist is broken;
o
If the load weight exceeds the permitted lifting capacity.
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7.2
Lowering a load
Errore. Il segnalibro non è definito.
During operation, the operator must use the operating chain by standing
next to the
chain itself, at the same level as the toothed wheel.
Working under loads
IT IS STRICTLY FORBIDDEN to operate and/or stand under the load.
To lower the load move the up/down selector lever to DOWN pulling the control lever
up and down in
alternating movements until the load is resting on the ground.
To release the chain, so as to detach the hook from the load, rotate the chain pre
-
tensioning control anticlockwise, until the hook is released.
If very intense lowering is carried out, with v
ery heavy loads, the lowering brake may
overheat. In these cases, adequately cool the brake.
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8
MAINTENANCE
The purpose of this chapter is to provide all the information on maintenance procedures and
the frequency required for the
Lever chain hoist.
Mainten
ance and repairs must be performed by qualified personnel.
Maintenance with machine unloaded
Carry out inspection, maintenance and cleaning operations only when the Hoist is safely
positioned on a workbench.
8.1
Routine maintenance
INTERVENTION
Frequency
Daily
Weekly
Monthly
1.
General visual inspection
X
2.
Check that plates are clearly visible and
legible
X
3.
General cleaning
X
4.
Lubrication and greasing
X
5.
Checking the gears
X
6.
Check the wear of the lowering brake
X
7.
Checking hook wear
X
8.
Ch
ecking the chain lengthening
X
1.
General visual inspection:
check the general condition of the machine, if there are
any damaged or missing parts.
2.
Check that plates are clearly visible and legible:
the plate on the machine must
be perfectly visible and
legible. It is therefore necessary to keep it clean and ask the
maintenance officer for a replacement if it is illegible.
3.
General cleaning:
cleaning is necessary to free the structure and moving parts from
the accumulation of dust, dirt and stains caused b
y excess lubricants. Cleaning should
be done with the use of means, equipment and detergents or solvents commonly used
in the cleaning of industrial equipment.
4.
Lubrication and greasing:
after cleaning the hoist and lifting chain, it is necessary to
grease
the moving parts of the machine, i.e. the lifting chain, pins, shafts, wheels and
gears; be careful to protect the surfaces of the brake clutch discs during lubrication of
the hoist, to prevent them from becoming dirty.
5.
Checking the gears:
periodically che
ck that the gears are not worn and that there are
no foreign materials. For example: wire, twine, etc. can affect normal rotation and are
therefore removed.
6.
Checking the wear of the lowering brake:
the brake mechanism should be
inspected regularly by a qua
lified maintenance technician to avoid malfunctioning and
the consequent falling of the load.
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7.
Checking hook wear:
it is necessary to check that the upper and
lower hooks are not worn, that there are no cracks and/or splits or
abnormal deformations and tha
t the closure safety device on both
hooks still works properly. Check that the opening dimensions of the
hook fall within the following dimensions otherwise replace the hook.
Figure
10
–
Hook deformation measurement.
ARTICLE
OP
ENING STANDARD (mm)
OPENING LIMIT (mm)
0237/05
27
29.7
0237/15
35
38.5
8.
Checking the chain lengthening:
If the chains have lengthened beyond a permitted
percentage they must all be replaced.
1.
Figure
11
–
Chain measurement
.
The lengthening must be within the following parameters: (values
based on the
measurement of ten links as described in the figure:
ARTICLE
DIAMETER
(mm)
LENGTH STANDARD (mm)
LENGTH LIMIT(mm)
0237/05
Ø 5
150
153
0237/15
Ø 7
180
183.6
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9
TROUBLESHOOT
ING
The following table shows the type of defect / problem, possible causes, and possible
remedies for the malfunction. The table is a useful aid for the maintenance technician when
looking for problems with the machine.
ERRORE. IL SEGNALIBR
O NON È DEFINITO.
Fault
Cause
S
olution
The control lever can not be
pulled beyond a certain
point.
Something has caught on the
load.
A part of the hoist is broken.
Load weight exceeds
permitted load capacity.
Remove the obstacle.
Have a specialist technician
repair the hoist.
Ensure lo
ad weight does not
exceed the permitted load
capacity.
The load does not rise to the
desired height.
Fault in the braking
mechanism.
Check the proper operation
of the ratchet gear and clutch
discs.
10
DECOMMISSIONING
10.1
Machine downtime
ERRORE. IL SEGNALIBR
O NON È DEFINITO.
Before a period of inactivity, deposit the Lever chain hoist in the warehouse. Proceed as
follows to prepare the machine for warehouse storage:
remove any load from the hoist;
unhook the hoist from the support structure;
protect movi
ng parts with grease and/or lubricating oil;
protect working parts and the chains with an anti
corrosive protective liquid;
store in a dry place, free from dust and atmospheric agents.
10.2
Disassembly and disposal of materials and components
If the machine is
to be scrapped, its parts must be differentiated for disposal.
Respect the environment!!
Contact a specialist centre for the collection of metallic materials.
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